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TRANSCRIPT
HEADLINE LOREM IPSUM
32
MEFKON PRODUCT RANGE
· Ladle preheater/drier
· Tundish preheater/drier
· Scrap drier
· Snorkel preheater
· Two-stage recuperator
· COB lance
· Burner / multifuel burner /
oxygen burner / flameless burner
· Combined air/oxygen burner
COMPANY
Redundant control of burner
· Energy-saving motors· Frequency controller· Energy savings potential: 45 % – 65 %
Engineered vessel covering· Ultra light concrete reduces heat storage capacity
· Self-adapting heat shield
Redundant control of heating curve
Reduced number of wear parts lead to cost reductions
Modern burner technology· Reduction of gas usage: up to 75%· Reduction of CO
2: up to 75%· Reduction of NOx: up to 90%
EFFICIENCY
MEFKON designs and manufactures systems for the drying and
heating of all types of vessels with refractory materials during the
production of hot metal and steel.
Our products are based on the Emission Optimised Heating Tech-
nology (EOHT) we have developed. This technology enables our
customers to dry and heat with unparalleled efficiency in terms of
emissions and energy consumption. As MEFKON is not associated
to a refractory materials producer or producer of components
we are therefore able to integrate highest-quality products from
burner, control and refractory technologies into our systems.
MEFKON EOH Technology was developed by a team of industry
experts with extensive, long-standing experience in the
refractories industry. Each team member has on-site experience in
steelworks. Combined, we have commissioned, maintained and
repaired more than 1000 heating and drying systems.
This experience and the holistic technical understanding of all
relevant processes and influencing factors form the basis for our
engineering services.
Tundish drying station, TWIN blower system
54
PRODUCTS AND ENGINEERING PRINCIPLES
MEFKON PRODUCT RANGE
· Ladle preheater as horizontal or vertical type as well as
special constructions
· Vertical ladle drier for drying processes of monolithic-lined
ladles as well as tempering process of brick-lined ladles such
as dolomite-lined ladles, with secondary air and /or oxygen
injection, a rim suction system and post combustion
· Zero-emissions drying station (in addition to the post
combustion inside the ladle, an external combustion
chamber is used)
· Ladle housings (part of the Zero-emissions drying station)
· Tundish preheater multi-burner system
· Tundish drier for drying processes of monolithic-lined
tundish, or drying of other materials
· Mobile burner systems
· SEN and ladle shroud oven and preheating systems
· Special burner constructions and multifuel burner
· Air burner with continuous oxygen enrichment
· Oxygen burner systems with or without water cooling
· Flameless oxygen burner systems
· Two-stage radiation recuperator
· COB lance
· Flares for waste gas burners
· Torpedo ladle heaters
· Launder heater and drier
· Valve racks for burner media
ENGINEERING PRINCIPLES
Optimised operation
(at the touch of a button)
· PLC controlled via touch panel and TCP/IP communication
· Web access to all recorded heater data for the best possible
maintenance support
Easy maintenance
(clear and logical design of heating system)
· Reduced number and increased lifetime of wear parts
· Safe and easy access to all heater components
· Monitoring of control pressures in order to determine mainte-
nance requirements in advance
· Data exchange with MEFKON server for external trouble-
shooting
Highest safety standards according EN746-2:2010
· Only DIN DVGW certified components are used
· Safety analyses according to machinery directive 2006 / 95 / EC
performed by external experts
· Flame monitoring of the main burner for continuous flame
monitoring (heating processes > 24h)
· Tightness check of gas valves after every burner off
· Continuous temperature control
· High-temperature monitoring via double thermocouple
· Continuous power regulation
· Gas /air or Gas /oxygen ratio monitoring
· Only SIL certified components used
Highest efficiency through
· A self-adapting heat shield suspension such as a
cardanic suspension
· Gapless covering of the vessel due to a special hydraulic control
and a lid mounting similar to a cardanic suspension
· Ultra low-weight concrete lining of the heat shield for a
reduction of the thermal power input
· Stoichiometric gas/air ratio control over the whole power
regulating range with continuous temperature control
· Two-stage exhaust gas radiation recuperator
· Energy recuperation caused by a special flame shape
· Combined air/oxygen burner
· Very high burner power regulating range
(approx. 1 : 11 between max. and min. load)
· Additional savings due to frequency-controlled blowers
(savings in electricity of up to 65 %)
· Recommendation for the use of oxygen burner systems
(savings in gas of approx. 70 %)
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Torpedo ladle preheating / drying station with 2-stage radiation recuperator
Hydraulic lid swivelling approx. 30°
Burner power 2 x 1.200 kW
Heating times between 8,0 h up to 100 h
Max. temperature 1.200°C
1
2 Mobile preheating/drying station, secondary air, TWIN blower system, handling by overhead craneBurner power 3 x 350 kWSecondary Air approx. 1.500 Nm3/h
Heating times between 8,0 h up to 100 h
Max. temperature 1.000 °C
PRODUCTS
3 Vertical ladle preheating / drying station, secondary air, TWIN blower system
Hydraulic lid swivelling 90°
Burner power 2.500 kW
Secondary Air approx. 1.500 Nm3/h
Additional oxygen injection for tempering
Heating times between 8,0 h up to 100 h
Max. temperature 1.200 °C
1) Torpedo ladle
3) Pig Iron Ladle
2) Chute
98
Vertical converter preheating / drying
station with combined air / oxygen
burner
Hydraulic lid swivelling 90°
Burner power 600 kW in Air mode
Burner power 1.500 kW in Oxygen mode
Additional oxygen enrichment for tempering
Heating times between 24,0 h up to 100 h
Max. temperature 1.300 °C
4
Oxygen control line
for converter lance
Max. 10.000 Nm3/h
Water cooling lines inlet and outlet for converter lance
100 m3/h
5
PRODUCTS
Horizontal ladle preheater with
2-stage radiation recuperator
Pneumatic lid movement
Approx. 1.000 mm stroke
Burner power 2.000 kW
Fast heating of ladles being in circulation
Max. temperature 1.200 °C
Ar / N2 ladle stirring
control line for porous plug
High precision mass flow control system
6
7
5) O2 Control Line
7) Porous Plug
6) Ladle
4) Converter
1110
PRODUCTS
Flare stack burner DN400
Ignition burner power 2 x 100 kW
8
Combined Oxygen
burning / blowing lance
Burner power 2.400 kW
Oxygen blowing rate 2.000 Nm3/h @ 10 bar
Max. temperature 1.400 °C
9
Ar / N2 RH lift gas control line
High precision mass flow control system
flow and pressure indication per line
11
Vertical RH-vessel
preheating / drying station
Hydraulic lid swivelling 90°
Burner power 1.200 kW
Heating times between 24 h up to 100 h
Max. temperature 1.200 °C
10
9) O2 Lance
10) RH Vessel
11) Lift Gas Control Line
8) Waste Gas Line to Flare Stack Burner
1312
PRODUCTS
Vertical ladle preheating station
with 2-stage radiation recuperator
Hydraulic lid swivelling 90°
Burner power 2.500 kW
Fast heating for ladles right before tapping
Max. temperature 1.200°C
12
Ladle shroud heater / drier
Automatic ignition and flame monitoring
Burner power 70 kW
Heating times between 45 min up to 120 min
Max. temperature 800°C
13
Tundish preheating / drying
station, secondary air
Hydraulic lid swivelling 90°
Burner power 4 x 350 kW
Secondary air approx. 1.000 Nm3/h
Heating times between 90min up to 240 min
Max. temperature 1.200°C
14
SEN heater
Automatic ignition and flame monitoring
Burner power 100 kW
Heating times between 45 min up to 120 min
Max. temperature 1.200 °C
15
14) Tundish
15) SEN
12) Ladle
13) Ladle Shroud
1514
MANUFACTURING PRINCIPLES, SERVICES AND SOLUTIONS
MANUFACTURING PRINCIPLES
MEFKON heating systems are designed and manufactured using
state-of-the-art technology.
Every MEFKON heater is based on the fundamental demands
of highest efficiency, lowest emissions and highest reliability.
Every single heating system is completely assembled, wired
and checked according to inhouse quality standards and final
functionality tests.
After recording the quality and functionality tests, the heating
system is dismantled into a few main components and prepared
for shipment.
Due to these extensive test procedures and the complete
assembly, MEFKON has minimised the time needed to construct
our products and put them into operation.
Tundish preheating station
SERVICE RANGE
· Spare parts provision for existing preheating / drying systems
· Heat shield repair and training for heat shield repair
· Maintenance / repair services for ladle and tundish
preheater / drier
· Commissioning service for ladle and tundish preheater /
drier
· Commissioning service for COB lances
· Efficiency analysis of existing preheating / drying systems
Our main task is to find an optimal solution, especially
when it comes to key issues such as a uniform temperature
distribution, shortened heating times and less stress / strain
tolerance of the refractory material and the efficiency increase
of the whole system.
The precise, smooth adjustment of the temperature control range
to the existing infrastructure parameters is the first step in systems
optimisation. Significant success factors include the reduction of
mass and the sealing of the burner lid. We have developed a new
and very robust burner lid, which contains up to 1–2 tonnes less
refractory material than conventional lids. This is possible without
making any compromises with respect to its sealing ability. In
addition it also achieves improved insulation efficiency. The
heated mass is reduced by 5– 6 %, which leads to a significant
reduction in energy consumption.
One further characteristic of MEFKON technology is its
construction aimed at low wear and tear and thus reduced
maintenance. All our products have a modular design which uses
moving parts as little as possible. Moreover, our products are
constructed based on preventive maintenance principles, allowing
for remote monitoring and early warning systems.
Burner technology is also key to achieving optimal system
configuration. We place very specific requirements on burner
manufacturers in order to integrate them into our systems.
MEFKON GmbH & Co. KG
Industriepark 70 –74 | 56593 Krunkel | GERMANY
Phone: +49 2687 92627 0 | Fax: +49 2687 92627 20
[email protected] | www.mefkon.com